Insulating light wall building elements

ABSTRACT

This light wall building construction element with insulation is to be used in the building of the internal and external walls of buildings and in the ceiling asmolen application. The objective is to provide heat, sound and water insulation with a single product without using additional insulation materials and to reduce the load of the building by a considerable degree. Polystyrene strapor or polyurethane materials used as insulation materials in the construction sector are used in the production of the external unit ( 1 ) of the product. Foam concrete which holds a special place as a construction material, or light concrete made of light aggregate with pores is manufactured as an internal unit ( 7 ) and is installed to the empty volume of the external unit ( 1 ) in sufficient quantities while it is still wet. When the concrete inside the internal unit ( 7 ) gets hard, the production process of the product is completed.

This invention concerns new perspectives on construction element that has high insulation properties to be produced according to construction standards and measures for the building of internal and external walls and the Asmolen ceiling applications.

In order to construct the internal and external walls, in today's buildings, brick made of clay, cement based briquette made of light or heavy aggregate (sand-stone-BIMS-particular straphor), asmolen or block material made of asmolen or gas and foam concrete and concrete made of light aggregate with pores are used. The Standard Numbers of the Turkish Standards Institute (TSE) and the unit volume weight are given in TABLE 1 as documents and sources of the current technology.

TABLE 1 THE STANDARD NO'S AND UNIT VOLUME WEIGHTS OF THE BUILDING MATERIALS AND BUILDING SECTIONS NAME OF MATERIAL OR THE COMPOSITION Kg/m³ LARGE SIZED CONSTRUCTION ELEMENTS CONCRETE Normal concrete (conforming to TS 500) concrete made of Equipped 2400 natural aggregate or grit Unequipped 2200 Concrete made of light aggregate and without adding quartz 800-2000 sand (aggregate which conforms with TS 1114) Concrete made of only through the use of dilated perlite 300-1600 without adding quartz sand (Conforming to TS 3649) Concrete made of clinker 1200 Light concrete made with aggregates without pores (w/vacuum) 1600-2000  Concrete made with light aggregate with pores without adding 600-2000 quartz sand Concrete made with the use only natural bims without adding 500-1200 quartz sand (conforming to TS 3234) including construction elements conforming to (TS 2823) Concrete made of sawdust from wood saw or planers 400-1200 Concrete made of rice husks 600-700  Gas concrete fortified with steam (including construction 400-800  elements conforming toTS 453) CONSTRUCTION PLATES AND SHEETS Construction sheets made of gas concrete (conforming to TS 500-800  453) with normal mortar and adhesive Wall plates made of light concrete 800-1400 Wall sheets and blocks made of plaster of paris (including those 600-1200 with pores, holes, filling or aggregate) (conforming to TS 451, TS 452, TS1474) Walls plates made of plaster of paris with dilated perlite 600-900  aggregate added (conforming to TS 3682) Carton plates made of plaster of paris 900 WALL PAPERS Stone wall made of rough stones 2400 Stone wall made of concrete 2200 Stone wall made of light stones 800 Stone walls made of bricks conforming to TS 704, TS 705 full 1800-2200  clinkers, vertical holed clinker (TS 4562) ceramic clinker With full or vertical holed bricks conforming to TS 704, TS 705 1200-2000  Walls made of vertical holed bricks with AB and W class bricks 700-1000 with the use of mortar conforming to (TS 4377 and TS 4916) Walls made of horizontal holed bricks (TS 4563) 1000 Walls made of chalk-sandstone (conforming to TS 808) 700-2200 Walls made of gas concrete wall blocks (conforming toTS 453) 400-800  Walls made of concrete briquettes or wall blocks wth the use of 500-2000 light filled (conforming toTS 406), concrete with natural I bims conforming to TS 2823 Walls made of concrete briquette or wall blcoks made of 500-800  dilated perlite concrete filled blocks conforming to TS 3681 Walls made of light concrete blocks with vacuum conforming 500-1400 to (TS 2823) Walls made of Normal concrete briquettes and blocks with ≦1800 vacuum conforming to (TS 406) HEAT INSULATING MATERIALS Sheets made of wood shaving conforming to (TS 305) 360-570  Polystyrene-particle foam (TS 7316) ≧15 Hard foam sheets made of polyurethane-phenol resin (TS ≧30 2193) (TS 10981) Insulation materials made of mineral and vegetal fibers (TS  8-500 901)

The individual use of each above materials as construction elements for wall building causes some technical and/or financial problems. The technical and other problems to be solved by the use of this invention are as follows:

1—Low insulation feature,

2—Formation of heat bridge at the joints owing to the mortar,

3—Requires additional insulation for the reasons cited in paragraphs 1 and 2, and will increase heating and cooling expenses if additional insulation is not performed,

4—Because of their heavy weight they add additional burdens to the building and pose threat to life safety, and cause cracks in the walls as the building settles or shakes,

5—The internal and external surfaces do not hold plaster well and easily and/or requires a rough plaster,

6—Long and costly labor, such as (wall construction, insulation, application of rough plaster), higher construction material costs (amount of concrete, amount of equipment, insulation material, amount of rough plaster),

The heat insulation coefficients of the construction materials available in the market are given in TABLE 2.

TABLE 2 HEAD INSULATION COEFFICIENT CONSTRUCTION MATERIAL (W/mK) Cement Mortar 1.4 Lime mortar, lime ″C cement mortar 0.87 Plaster with Perlite 400 Kg/m3 400 Kg/m Plaster 0.14 with Perlite 400 Kg/m3 Plaster with Perlite 400 Kg/m3 0.16 Plaster with Perlite 400 Kg/m3 0.2 Plaster with Perlitle 400 Kg/m3 0.24 Plaster with Perlite 400 Kg/m3 0.29 Made of normal concrete of natural aggregate or by 2.1 using grit, equipped Made of normal concrete of natural aggregate or by 1.74 using grit, unequipped Plaster of paris mortar, plaster with lime mortar 0.7 Plaster made with the use of plaster of paris only 0.35 Sheets made of Polystren Hard Foams (PS) 0.04 Glass foam sheets 0.052 Foam Sheets (XPS) with synthetic rough-channels 0.031 TS-453 Gas Concrete 0.16-0.19 Vertical Holed Bearing Bricks in TS-705 Standard 0.5 1200 Kg/m3 Vertical Holed Bricks in TS-4563 Standard, 600 kg/m3 0.45 W Class Vertical Holed Telescope Bricks in TS-4377 0.27 Standard, 800 Kg/m3, Made of Normal Mortar W Class Vertical Holed Telescope Bricks in TS-4377 0.24 Standard, 700 Kg/m3, Made of Normal Mortar W Class Vertical Holed Telescope Bricks in TS-4377 0.21 Standard 800 Kg/m3, made of TS-4916 mortar W Class Vertical Holed Telescope Bricks in TS- 0.18 4377 Standard, 700 Kg/m3, made with TS-4916 mortar Plaster of paris carton plates (conforming to TS 0.21 452) 900 Kg/m3 Source TS 825

TABLE 3 Heat Insulation Materials Product Standard Glass wool, TS 901 EN 13162 Stone wool TS 901 EN 13162 Expanded polyesther (EPS), TS 7316 EN 13163 Extruded Polyesther (XPS), TS 11989 EN 13164 Polyurethane (PUR), TS EN 13165 Phenol Foam TS EN 13166 Glass Foam TS EN 13167 Sheets made of wooden fiber, TS EN 13168 Dilated Perlite (EPB), TS EN 13169 Dilated Mushroom (ICB) TS EN 13170 Sheets made of wooden wool TS EN 13171

The product standards of the primary insulation materials used in heat insulation are given in TABLE 3.

The known construction materials (bricks, briquette, asmolen gas concrete) have densities between 400-2200 mg/m3 (TABLE 1). While this material density brings significant loads to the bearing system of the building, its coefficient of insulation, in accordance with TS 825 Heat Insulation regulations, which is gaining more and more importance in Turkey, is extremely insufficient as it can be seen in TABLE 2. Two important reasons for lack of insulation are as follows:

1—The cement based mortar at the joints after the construction causes a heat bridge. 2—The second thing is the different ratios of materials and common techniques in the process of the product cause low insulation features. In order to prevent this situation you need to apply additional insulation for heat-sound-water insulation at added labor material costs. If you avoid performing the additional insulation you tend to incur much bigger expenses in the long run because of the loss of heat.

According to TS 825 of the Turkish Standards and norm number 4108 of the German DIN, insulation materials such as stonewool, extruded polystyrene, expanded polystyrene, glass wool, polyethylene, polyurethane, glass foam whose insulation values are less than (λ) 0.060 kcal/mh° C. are called “heat insulation materials” and those with higher values are called “construction materials”.

In order for the heat insulation materials to achieve the desired performance, their vacuum ratios have to be high, their densities low and their ratio of humidity have to be low. Construction materials manufactured with only heat insulation do not achieve the desired results. In addition to heat insulation, the importance of humidity flow and condensation are other features that are sought in insulation materials as well. If the material has a high steam diffusion resistance factor this reduces the effect of the steam, and is less affected by the changes in heat and the density has to be high in order to store the heat and the heating temperature is expected to be high also. It seems not possible for one single material to possess this and every unit does not have similar features in itself.

The most important task is performed by the external construction components in protecting the buildings from the effects of heat/cold. Walls and windows being the primary, the ceiling, chimney, and the components that come into contact with the ground/floor protect the building from the external effects. The heat insulation, heat storage and heating-cooling features of the materials that constitute these components, in respect to heat insulation, are very important.

When used properly, heat insulators are the kind of materials or composition of materials which convey, transfer and/or which reduce the passing of energy with the type of heat rays. These insulation materials could be made of fiber, granules, film layers, either in blocks or single parts, with open-closed cells, connected to each other either chemically—mechanically or supported with mixed materials.

Taking into account the facts given above and according to the best known technology, a new insulator light wall construction material has been designed by combining a construction material with superior properties with an insulator which provides superior insulation to be used instead of the various construction materials which provide poor insulation and which do not reduce the cost when used individually. The superiority of the material in comparison to other similar products are listed below.

1—The weight of the new product is between 250-350 kg/m³ while the weight of the other products varies between 400-2200 kg/m³.

The 1 m³ or 1 m² weight of the product is at a minimum 20% lighter than 1 m³ or m² of gas concrete known and accepted actually as the lightest wall construction material and is 260% lighter than the other materials. Thus, the load of the building is decreased at these ratios as well. The reduction in the load of the building has to bear will also decrease the quantities of concrete and filling equipment used in the bearing system and as a result the total weight of the building will also be reduced. This deduction means that significant savings may be achieved in the total cost of the building.

2—The reduction in the unit weight will contribute to work health and safety because it will facilitate the carrying of the material and construction of the wall and by reducing the load of the building and the wall system it will provide safety to a great degree in the case of earthquakes.

3—Since the new construction material is light and flexible it will prevent cracks in the walls as the building settles in its foundation or as it shakes.

4—It will achieve high standard heat, sound and water insulation in the walls of the buildings. This will preclude additional insulation process, additional labor and additional cost.

5—The product, with its horizontal and vertical axis will reduce the cost of labor, insulation costs, and heating and cooling by preventing heat loss at a maximum.

6—It will reduce production and transportation costs because it is much lighter than the other products of the same volume.

The wall construction elements have been shaped in the manner given in the enclosed figure for the invention to achieve its intended purpose and of these;

FIG. 1—is the picture of the external unit made of polystyrene or polyurethane material.

FIG. 2—Is the picture of the final product after the internal unit made of foam concrete or light aggregate concrete is installed on the external unit.

FIG. 3—picture of the product from the top.

FIG. 4—picture of the product from the bottom.

FIG. 5—picture of the product from the left and rights sides.

FIG. 6—picture of the product from the front and the rear.

The explanations of the figures have been numbered and their corresponding explanations are as follows:

1—Polystyrene or polyurethane external unit

2—The thickness of the external unit

3—The bottom surface of the external unit

4—Top/bottom telescope teeth of the external unit

5—Left-right side telescope teeth of the external unit

6—Upper surface of the external unit

7—Internal unit made of foam concrete or concrete with light aggregate

8—The internal and external plaster surfaces of the product

9—Plaster holding channels

The external of the product (1), shall be manufactured with (Expanded, Extruced Polystren Stropor) or one of the polyuretahne foam tight materials in appropriate different sizes (FIG. 1). The thickness (2) of the external unit shall be between 1 and 5 cm. If EPS is used in the external unit (1) then the known procedures shall be applied; the granular raw materials shall be expanded beforehand with steam and shall be in one of the settling silos for the product to settle. Later, the material treated beforehand shall be injected and compacted into forms and shall be placed in the oven after it reaches a certain degree and removed from the forms once the product takes the final shape. If polyurethane foam is used in the production of external unit (1) two or more chemical liquids shall be mixed together in specific ratios. This mixture shall then be placed in forms and closed. After a chemical reaction the volume will expand and cover the form entirely and turn from liquid to solid form and shall be removed from the form as an interim product. The bottom surface of the external unit (3) is covered to prevent the creation of the vertical mortal heat bridge. The upper surface of the external unit (6) whose four corners and the base are in the shape of a monoblock is left open If the internal unit (7) is made of foam concrete or concrete made of light aggregate the known methods shall be used; The wet foam manufacture with synthetic protein and/or fluorprotein foam extract, shall be processed in a concrete plant according to the concrete recipe (with natural and sifted sand, bims, eps polystyrene particles, volatile ash, etc) and shall be placed in the external unit (1) while it is still wet without being reinforced. When the concrete placed in the external unit (1) hardens the product shall have taken its final form. The unit volume weight of light foam concrete is between 400-500 kg/m3. The concrete of the internal unit (7) may be produced by wet foam made of synthetic, protein and/or fluoroprotein foam extract and/or with all types of light aggregate (natural and crushed sand, bims, eps polystren particles, volatile ash etc) and used in the product. In this process the unit volume weight of the concrete varies between 500-1000 kg/m³.

The top and bottom telescopic teeth (4) and the left-right telescopic teeth (5) of the insulated and light construction materials designed and produced in the manner explained above shall be bounded during the construction of the walls of the buildings and shall be connected with each other by confining the connections inside the building mortar. The product has channels (9) in the shapes and depths to insure the product sticks to the surface (8) on which plaster is to be administered. The product to be used on the ceiling ASMOLEN shall be manufactured with the same materials in the same manner in different sizes only.

If the product is manufactured by combining polystyrene or polyurethane whose unit volume density is 15-30 kg/m3 and heat insulation coefficient is 0.031-0.04 W/mK with concrete made of foam concrete or with light aggregate with pores and whose unit volume density is 400-500 kg/m3 and heat insulation coefficient is 0.16-0.19 W/mk in the manner and fashion explained above; the new combined material will have a weight of 300-350 kg/m3 and a heat insulation of 0.06-0.08 W/mK shall be a new product which will also serve as an insulation material. If the new material is used in the wall system of the buildings it will provide heat-sound and water insulation, reduce the cost of materials and labor and the expenses incurred from heat loss, and will provide high quality, simplicity, comfort, safety of life and commodities. 

1-3. (canceled)
 4. A building construction element in the form of an external unit (1) made out of a singular material in the shape of a monoblock box with a covered bottom surface (3) and an open top surface (6), the element being in the form of an external unit (1) receiving poured concrete as a mould in situ, the element further comprising top and bottom telescopic teeth (4) and left and right side telescopic teeth (5) bound together during construction of a wall system, the teeth (4, 5) binding neighboring elements together by becoming confined inside a wall construction mortar.
 5. A building construction element as in claim 4 wherein the element is made of EPS or a polyurethane-foam based material.
 6. A building construction element as in claim 4 wherein the element has a density in the range of 15-30 kg/m³.
 7. A building construction element as in claim 6 wherein internal and external surfaces (8) of the element comprises channels (9) having a depth, the channels facilitating sticking of the plaster being administered.
 8. A building construction element as in claim 7 wherein the poured concrete into the element, the latter serving as a mould in situ, comprises concrete foam or light aggregate with pores and is designed with synthetic, protein and/or fluoroprotein foam extract as wet foam, water, aggregate and cement.
 9. A building construction element as in claim 8 wherein the aggregate in the poured concrete comprises natural and crushed sand, bims, EPS, polistren particle or volatile ash.
 10. A building construction element as in claim 9 wherein the poured concrete has a unit volume weight in the range of 400-500 kg/m³.
 11. A building construction element as in claim 10 wherein the poured concrete is installed into the external unit (1) as an internal unit (7) without iron reinforcement and in wet condition. 